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Tahoe / Yukon Service Manual

Front Differential Carrier Cover and Gasket Replacement

Single Use Fasteners and Components Front Differential Carrier Cover Gasket Removal Procedure

  1. Raise and support the vehicle. Lifting and Jacking the Vehicle
Front Differential Carrier Cover and Gasket Replacement — figure 1
Front Differential Carrier Cover and Gasket Replacement — figure 1
  1. {without RC1} Remove the underbody skid shield: 2.1. Underbody Skid Shield Bolt (1) » Remove [4x] 2.2. Underbody Skid Shield (2) » Remove
Front Differential Carrier Cover and Gasket Replacement — figure 2
Front Differential Carrier Cover and Gasket Replacement — figure 2
  1. {with RC1} Remove the underbody skid shield: 3.1. Underbody Skid Shield Bolt (1) » Remove [2x] 3.2. Underbody Splash Shield Bolt (2) » Remove [2x] 3.3. Underbody Skid Shield (3) » Remove
Front Differential Carrier Cover and Gasket Replacement — figure 3
Front Differential Carrier Cover and Gasket Replacement — figure 3
  1. Disconnect and reposition the 2 power steering wiring harness electrical connectors (1).
Front Differential Carrier Cover and Gasket Replacement — figure 4
Front Differential Carrier Cover and Gasket Replacement — figure 4
  1. Disconnect the 2 retainers (1) and reposition wiring harness.
  2. Position a drain pan under the front differential carrier (2).
Front Differential Carrier Cover and Gasket Replacement — figure 5
Front Differential Carrier Cover and Gasket Replacement — figure 5

  1. Front Differential Carrier Cover Bolt (1) » Remove [10x]

  2. Front Differential Carrier Cover (3) » Remove

  3. Front Differential Carrier Cover Gasket (2) » Remove and DISCARD

  4. Clean the front differential carrier, front differential carrier cover, and front differential carrier magnet. Installation Procedure

  5. Prepare the 10 front differential carrier cover bolts (1) for installation as follows: 1.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 1.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 1.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 1.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

  6. Front Differential Carrier Cover Gasket (2) » Install NEW

  7. Front Differential Carrier Cover (3) » Install

  1. Front Differential Carrier Cover Bolt (1) » Install and tighten [10x] — Fastener Specifications
Front Differential Carrier Cover and Gasket Replacement — figure 6
Front Differential Carrier Cover and Gasket Replacement — figure 6
  1. Front Differential Carrier Oil Filler Plug (1) » Remove
  2. Fill the front differential carrier with the appropriate amount and type of axle lubricant: Approximate Fluid Capacities Adhesives, Fluids, Lubricants, and Sealers
  3. The gear lubricant level should be 16–22 mm (0.6-0.9 in) below the plug opening.
  1. Front Differential Carrier Oil Filler Plug (1) » Install and tighten — Fastener Specifications
Front Differential Carrier Cover and Gasket Replacement — figure 7
Front Differential Carrier Cover and Gasket Replacement — figure 7

  1. Reposition the wiring harness and connect the 2 retainers (1).

  2. Reconnect and reposition the 2 power steering wiring harness electrical connectors (1).

  3. {with RC1} Install the underbody skid shield: 11.1. Underbody Skid Shield (3) » Install 11.2. Underbody Splash Shield Bolt (2) » Install and tighten [2x] — Fastener Specifications 11.3. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

  4. {Without RC1} Install the underbody skid shield: 12.1. Underbody Skid Shield (2) » Install 12.2. Underbody Skid Shield Bolt (1) » Install and tighten [4x] — Fastener Specifications

  5. Remove the support and lower the vehicle.